Adjustable Cleat System

ABSTRACT

An adjustable roofing cleat system with a retainer and an extension plate. The retainer has a top panel and a front panel that extends downward. The retainer can be installed on a roof edge over a fluid impermeable membrane with the front panel extending downward at the front edge of the building and an aesthetic fascia cap of a first size mounted over the retainer. The extension plate can be attached in a face-to-face abutment with the front panel of the retainer with the extension plate extending past the front panel to form an extended cleat. An aesthetic fascia cap of a second larger size can be attached to the extended cleat without requiring a new retainer.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent Application No. 62/244,350 filed Oct. 21, 2015 for Adjustable Cleat System, the entire content of which is included herein by reference.

BACKGROUND

This disclosure relates generally to roofing cleats for implementing waterproofing at an edge of a building. More particularly, the present disclosure relates to cleat hardware which allows adjustability to accommodate cover members, such as fascia caps, of different sizes.

For fascia systems to which the present disclosure relates, cleats are spaced and secured on top of a fluid impermeable membrane across the peripheral edge of a roof. Fascia caps, which are typically in the form of pre-determined transverse lengths such as, for example, ten-foot lengths, are mechanically mounted over the cleats. Water, which passes between the ends of the fascia caps, flows onto the roof. The fascia caps are typically resiliently secured by lower hook-like flanges which engage lower terminal flanges of the cleats for securing the caps to the top of the wall. Fascia caps serve a multitude of purposes in such systems, including providing an additional fluid-proofing layer covering screw holes or other openings in the cleat and improving aesthetics of the building structure.

Fascia caps are manufactured in many sizes for both functional and aesthetic purposes. In practice, this creates a challenge for installers, as a different sized cleat is needed to accommodate every size of fascia cap. There is thus a need for a cleat system that is adjustable for accommodating fascia caps of different sizes, while reducing the overall number of cleats required for each size fascia cap.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a representative embodiment of the disclosed adjustable cleat;

FIG. 2 shows a variety of embodiments of the disclosed adjustable cleat from a side profile, emphasizing different configurations of hook members;

FIG. 3 shows another embodiment of the universal adjustable cleat;

FIG. 4 depicts a typical installation of the assembled cleat with extension of FIG. 3 in a fascia system on a flat roof;

FIG. 5 shows preferred dimensions of several embodiments of the universal cleat; and

FIG. 6 depicts a prior art fascia system and installation thereof.

DETAILED DESCRIPTION

Among the benefits and improvements disclosed herein, other objects and advantages of the disclosed embodiments will become apparent from the following wherein like numerals represent like parts throughout the several figures. Detailed embodiments of an adjustable cleat and system for use with fascia are disclosed; however, it is to be understood that the disclosed embodiments are merely illustrative of the invention that may be embodied in various forms. In addition, each of the examples given in connection with the various embodiments of the invention which are intended to be illustrative, and not restrictive.

Throughout the specification and claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise. The phrase “in some embodiments” as used herein does not necessarily refer to the same embodiment(s), though it may. The phrases “in another embodiment” and “in some other embodiments” as used herein do not necessarily refer to a different embodiment, although it may. Thus, as described below, various embodiments may be readily combined, without departing from the scope or spirit of the invention.

In addition, as used herein, the term “or” is an inclusive “or” operator, and is equivalent to the term “and/or,” unless the context clearly dictates otherwise. The term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise. In addition, throughout the specification, the meaning of “a,” “an,” and “the” include plural references. The meaning of “in” includes “in” and “on.

Further, the terms “substantial,” “substantially,” “similar,” “similarly,” “analogous,” “analogously,” “approximate,” “approximately,” and any combination thereof mean that differences between compared features or characteristics is less than 25% of the respective values/magnitudes in which the compared features or characteristics are measured and/or defined.

The adjustable cleat 10 includes a retainer 12 attached to a universal plate 14. The retainer 12 comprises a flat transverse top panel 16 and corresponding front panel 18 extending from a front edge substantially perpendicular to the top panel. A transverse flange 20 is formed in the top panel along the rear edge. The top panel 12 may also define a plurality of openings 22 for receipt of an elongate fastener (screw, nail). The front panel 18 is flat and defines a plurality of sets of slotted openings, 24, 26, transversely spaced along the front panel 18. The depicted embodiment shows two slots (24 and 26) in each set, however this is nonlimiting, as other embodiments exist with numerous additional slots in each set for added adjustability. The top slots 24 are all transversely aligned with a corresponding bottom slot 26. Advantageously, there may also be included a small recess above or below each slot 24, 26 for receipt of a dimple for aiding attachment of a universal extension plate 14 (not depicted).

The universal plate 14 includes a substantially flat outer panel 28 with a front face 28 a and rear face 28 b. A lower transversely extending flange 30 is formed as a bend in the terminal edge of the plate 14. The universal plate 14 also defines a plurality of rearwardly extending hooks or shovels 32 formed in the outer panel 28. In the depicted preferred embodiment, the hooks 32 may be formed as a bend from a three-sided notch cut in the sheet that forms the front panel 14. The hooks 32 are transversely spaced from each other along the outer panel 28 substantially the same distance that the sets of slotted openings, 24 and 26, are space from one another in the retainer front panel 18. The hooks 32 are therefore configured to mate within the top slot 24 or bottom slot 26 in each of the spaced sets to achieve a preferred distance between the terminal flange 30 from the top edge of the wall to and accommodate fascia caps of different sizes.

The hooks 32 may also include a dimple extending from the hook front surface in the direction toward the front face 28 b. The dimples are positioned to snap into a corresponding recess in the retainer front panel 18 to aid in mechanically retaining the universal plate 14 and retainer 12 relative to one another in the vertical direction once the retainer 12 and universal plate 14 are attached at the appropriate position.

FIG. 2 depicts several different embodiments of the universal cleat, with emphasis on the varying configurations of the universal panel hooks 32 a, 32 b, 32 c, 32 d. Also shown in FIG. 2 is an embodiment that includes a secondary alignment hook 36 extending in the forward direction from the retainer front panel 16 for receipt by a corresponding slot in the universal panel 14 (slot not depicted in side profile view). While also not depicted in the side profile view of FIG. 2, there may be a plurality of secondary alignment hooks 36 transversely space along the retainer front panel 18, each for receipt by a corresponding slot in the outer panel 28 of the universal plate. The position of all of the hooks and slots is not absolute.

FIG. 3 depicts an alternate preferred embodiment of the universal adjustable cleat 100. Similar to the previous embodiment, this cleat 100 comprises a retainer 112 and a universal extension plate 114. The retainer 112 has a flat top panel 116 and a front panel 118 extending therefrom defining a front face 118 a and rear face 118 b. In this embodiment, rather than the front panel extending directly from the top panel, the top panel 116 transitions to the front panel 118 via a compound V-shaped bend 117. The top panel 116 has a rear transverse flange 120 formed as a bend proximate its terminal edge. The front panel 118 is substantially flat and defines a plurality of receiving slots 132 spaced transversely across. The front panel 118 also defines numerous additional attachment openings 133. Though not depicted, the top panel 116 can also define attachment openings similar to the embodiment of FIG. 1. As shown, the front panel 116 also includes a terminal flange 121 in this embodiment, such that the retainer 112 may be installed by itself (i.e., without an extension plate attached) and engaged directly with a fascia cap.

The universal extension plate 114 has a flat outer panel 128 defining a front face 128 a and rear face 128 b. A lower transversely extending attachment flange 130 is formed as an S-shaped compound bend at the terminal edge of the outer panel 128. The outer panel 128 includes a plurality of transversely spaced hooks or shovels 124 that extend therefrom in the rearward direction. The shovels 124 are spaced from each other substantially the same distance that the slots 132 in the retainer front panel 118 are spaced from one another. Each of the slots 132 is configured to receive a shovel 124 when the plate 114 is mated with the retainer 112 with the rear face 128 b of the outer panel against the front face 118 a of the front panel in a surface-to-surface abutment. The longitudinal configuration of the retainer slots 132 is such that the universal extension plate 114 may arrive to a jobsite “pre-attached”, but not secured and be reciprocated vertically relative to the retainer 112 and out of engagement if the original retainer size is preferred to the extended size. The length from the top panel 116 to the terminal attachment flange 130 can be adjusted in this manner to accommodate fascia caps of varying sizes. The outer panel 128 also defines a plurality of attachment openings 134, each opening positioned to align with an attachment opening in the front panel 118 of the retainer for receiving an elongate fastener to be driven into the building face during installation.

FIG. 4 shows a typical installation of a fascia system that utilizes the disclosed universal cleat 100. Here, the cleat 100 is in the extended configuration with the universal plate 114 and retainer 112 engaged. A fluid impermeable membrane M is laid over a roofing structure R extending over the edge E. The universal cleat 100 is positioned on top of the membrane M with the top panel 116 extending onto the roof structure R and the front panel 118 with universal extension plate 114 over the front face of the building. An installer can thereafter secure the cleat 100 to the building via fasteners driven through the aligned front openings 133 and 134, thereby terminating the roof edge and sealing the membrane on the roof R. A decorative fascia cap 150 can be thereafter mounted over the cleat 100 via engaging the front terminal flange or transverse hook 158 with the transversely extending attachment flange 130, and then pivoting the cap 150 rearward until the rear flange or hook 156 snaps over the rear flange 120 for mechanical retention of the cap. When the cap 150 is installed, it is mechanically retained by the cleat 100 with the cap front face 154 covering the entire front panel 118 and outer panel 128 and the cap top plate covering the top panel 116. A series of cleats 100 and caps 150 may be installed extending transversely around the perimeter edge E of the roof R. FIG. 4 also depicts a pair of concealed joint splices 160, which are positioned between adjacent fascia caps to further protect against fluid infiltration. If fascia caps of a smaller dimension are preferred, the retainer 112 can be installed without the extension plate 114. Thus, the described system can accommodate twice as many types of fascia caps as known systems. While not described in detail below, the system of FIGS. 1 and 2 can be installed in substantially the same way.

The cleats 100 are principally dimensioned to accommodate walls of different dimensions. Various representative sizes of retainers are designated as cleat 112A, 112B, 112C and 112D in FIG. 5. In practice, the four depicted retainers that vary in terms of the length of their respective front panel 118 can be combined with a single disengageable extension plate 114 to accommodate eight different sizes of fascia caps. The front length of each of the retainers and extended cleats are noted in inches in FIG. 5. Of course the depicted sizes are only exemplary and the scope of the inventive adjustable cleat system is not limited in terms of specific sizes. The retainers 112 and extension plates 114 are preferably manufactured from 20 gauge to 16 gauge galvanized metal and, for some applications, 20 gauge to 16 gauge stainless steel. Another embodiment is manufactured from 0.050 inch aluminum for applications requiring added rigidity. However, as with the cleat lengths, none of the specific preferred sizes or materials should be viewed as limiting in scope.

With reference primarily to FIGS. 3 and 5, another aspect of the disclosed system 100 is a co-angular relationship of the terminal flange 121 and the attachment flange 130. That is, the terminal flange 121 is bent from the front panel 116 of the retainer 112 at an angle A. The attachment flange 130 in the extension plate 114 is bent initially from the front panel 118 at substantially the same angle A to form an intermediate portion 136. The intermediate portion 136 is then bent in the opposite direction at substantially the same angle A to form a lower portion 138 that defines a distal attachment edge. In this manner, the lower portion 138 of the extension plate 114 is substantially parallel to the front panel 118 when attached.

While a preferred embodiment has been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit of the invention and scope of the coverage. 

What is claimed:
 1. An adjustable cleat system, comprising: a retainer having a transverse top panel extending from a rear edge to a front edge, and a flat front panel extending downward from the front edge, the front panel defining a plurality of slots spaced from one another in the transverse direction; a universal extension plate with a flat surface extending to a terminal edge, the universal extension plate including a plurality of projections spaced from one another in the transverse direction, each projection configured for mating within a slot of the retainer front panel to maintain the extension plate in attachment with the retainer with the flat surface of the extension plate in face-to-face contact with the front panel and the terminal edge extending beyond the front panel to yield an extended cleat; and a fascia cap configured to securedly mount to the retainer and extension plate via mechanically mating at the top panel rear edge and extension plate terminal edge.
 2. The adjustable cleat system of claim 1, wherein the projections extend from in the extension plate as upwardly bent hooks.
 3. The adjustable cleat system of claim 1, comprising a plurality of slots transversely aligned and spaced downwardly from one another in the flat front panel, thereby providing a plurality of different downwardly spaced positions for receipt of a projection.
 4. The adjustable cleat system of claim 1, wherein the extension plate transitions via a compound S-shaped bend to the terminal end.
 5. The adjustable cleat system of claim 1, wherein the extension plate includes a plurality of projections extending rearward from the flat surface in the direction of the retainer and the front panel of the retainer includes a plurality of dimples for receipt of a projection.
 6. The adjustable cleat system of claim 1, wherein the front panel terminates in an outward flange bent from the front panel at an angle A.
 7. The adjustable cleat system of claim 6, wherein the extension plate is substantially S-shaped with a top portion and bottom portion separated by an intermediate portion and the intermediate portion is bent relative to the top portion at substantially the same angle A as the flange is bent from the front panel.
 8. The adjustable cleat system of claim 1, wherein the top portion and bottom portion of the extension plate are substantially parallel to one another.
 9. The adjustable cleat system of claim 1, wherein the retainer extends between approximately 3 and approximately 13 inches from the top panel to the front panel distal edge.
 10. The adjustable cleat system of claim 9, wherein the extended cleat is approximately 1 to approximately 3 inches longer from the top panel to the terminal edge than the retainer from the top panel to the distal edge.
 11. The adjustable cleat system of claim 1, comprising attachment holes in the front surface of the extension plate that are substantially aligned with attachment holes in the front panel of the retainer when the extension plate is attached to the retainer.
 12. A method for installing a roof edge fascia system on a substantially flat roofing structure having an outer edge, comprising: laying a fluid impermeable membrane over the roofing structure with a portion extending over the outer edge; providing a retainer member with a flat transverse top panel extending from a rear edge with an obliquely bent attachment flange to a front edge, and a flat front panel extending downward from the front edge, the front panel defining a plurality of slots spaced from one another in the transverse direction; providing a universal extension plate with a flat surface extending to a terminal edge, the universal extension plate including a plurality of projections transversely spaced from one another; attaching the universal extension plate to the retainer member via inserting a projection within a slot of the retainer front panel to maintain the extension plate flat surface against the retainer member front panel in face-to-face with the terminal edge extending beyond the front panel to yield a cleat; attaching the cleat to the roofing structure over the membrane with the top panel on the roofing structure and the front panel and extension plate hanging over the outer edge; and mounting a fascia cap over the cleat via mechanical engagement with the attachment flange and extension member terminal edge.
 13. The method of claim 12, wherein the front surface of the extension plate defines a plurality of attachment holes and the front panel of the retainer comprises a plurality of attachment holes substantially aligned with the attachment holes in the extension plate, comprising the step of driving an elongate fastener through aligned holes in the extension plate and retainer. 